Method and apparatus for producing an electrophotographic blade member

ABSTRACT

A method of producing an electrophotographic blade member includes a continuous molding groove in an peripheral surface and an endless belt, in which the blade member includes a polyurethane resin cured a polyurethane composition having a viscosity of 500-3,000 mPa·s and including A)-D), and a position at which the composition is injected is set, on the belt, opposing to the groove, the position being away from a portion at which the molding drum and the belt are first contacted on an upstream for a moving direction of the belt: A) polyisocyanate; B) adipate-based polyester polyol having a number average molecular weight of 1,000-4,000; C) chain extender having a molecular weight of 200 or less; D) isocyanurate-forming catalyst at 20 to 500 ppm and a urethane-forming catalyst at 200-1,500 ppm.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method and an apparatus for producingan electrophotographic blade member such as a cleaning blade and adeveloper amount regulating blade used in an image forming apparatus,such as an electrophotographic copier, a laser beam printer, and afacsimile, utilizing an electrophotographic process.

2. Description of the Related Art

Conventionally, as a developing apparatus in an image forming step of anelectrophotographic apparatus such as an electrophotographic copier, alaser beam printer, and a facsimile, there has been widely used oneincluding a developer carrier and a developer amount regulating blade.The developer carrier, such as a roller, is provided to be partiallyexposed at an opening portion of a developer container containingdeveloper (toner), and the developer amount regulating blade includes anelectrophotographic blade member which is made of a rubber material orthe like and is brought into contact with the surface of the developercarrier. Further, as a cleaning device in a photosensitive body cleaningstep of the electrophotographic apparatus, there has been widely used acleaning blade in which the electrophotographic blade member is joinedto a support body in order to remove residual toner on thephotosensitive body and repeatedly perform transferring after performingtransferring on a recording sheet.

The developer amount regulating blades are generally formed of a rubberplate, a metal thin plate, a resin plate, and a laminated body formed ofthose plates. The kinds of the developer amount regulating blades areselected depending on developer to be used. As one of the generally-useddeveloper amount regulating blades, there may be given one including anelectrophotographic blade member which is brought into press contactwith the developer carrier, and a supporting member for supporting theelectrophotographic blade member at a predetermined position. For theelectrophotographic blade member, a polyurethane resin is usually usedbecause it is excellent in mechanical characteristics such as abrasiveresistance.

The cleaning blade includes a metal supporting member for bonding theblade to the apparatus or the like, and an electrophotographic blademember which is formed of an elastic body and formed integrally with thesupporting member. For the electrophotographic blade member, thepolyurethane resin is usually used because it is excellent in abrasiveresistance and permanent deformation.

The above-mentioned electrophotographic blade including theelectrophotographic blade member made of the polyurethane resin isconventionally produced by any one of the following production methods.

One production method is called a centrifugal molding method. In thecentrifugal molding method, a raw material is put in a cylindrical dieto be rotated at high speed, and then is infilled on an inner peripheralsurface by the centrifugal force to be subjected to thermosetting, tothereby mold a thin cylindrical sheet. The cylindrical sheet thusobtained is released from the cylindrical die, subjected to secondarycrosslinking as needed, and then cut into a predetermined dimension.Thus, the electrophotographic blade member is produced. Then, by bondingone side edge portion of the electrophotographic blade member to thesupporting member by an adhesive or the like, the cleaning blade and thedeveloper amount regulating blade are completed as finished products.

Another production method is called a die molding method. In the diemolding method, the supporting member on which the adhesive or the likeis applied in advance is set in split dies, and the raw material isinjected into the split dies to be subjected to thermosetting, tothereby integrally mold the supporting member and theelectrophotographic blade member. After that, the split dies are opened,and the molded product is taken out. In order to ensure edge (edge line)accuracy, one side surface side of the molded product may be sometimescut after the molding.

Those methods leave room for improvement in terms of the followingpoints. First, the centrifugal molding method performs batch processing,which is difficult to realize continuous automation. Further, the diemolding method requires preparation of a large number of dies for massproduction, and also requires a curing oven. As a result, the size ofthe entire apparatus is increased, which leads to an increase in spaceto be ensured and apparatus cost.

As a conventional method for molding a polyurethane sheet continuously,the following method is given. Specifically, a liquid of polyurethaneprepolymer as a raw material component of thermosetting polyurethane anda liquid of a crosslinking agent are mixed and stirred to be dischargedinto the heated die having the continuous recessed sectional shape, andthen are heated and pressurized, to thereby continuously mold theelectrophotographic blade member having a constant width and a belt-likeshape. In this technology, it is possible to continuously mold theelectrophotographic blade member, and facilitate and simplify automationof a producing step. In addition, it is possible to reduce facilitycost.

In recent years, also in the technical field of electrophotography, costcompetition is being increased, and a production method with improvedproductivity is demanded to reduce cost. For the electrophotographicblade member using the polyurethane resin, an improvement of productionefficiency, which is realized by making the curing time shorter, anddownsizing of the apparatus are demanded.

However, in a case of using the raw material composition of thepolyurethane resin which is formed of the polyurethane composition withthe short curing time, when injected into a groove with a recessedsectional shape of a heated molding drum, the composition starts to curedirectly after being brought into contact with the molding drum. Thus,the curing progresses from the surface that is held in contact with themolding drum, and a difference is made in curing timing between thesurface held in contact with the molding drum and a surface that isthereafter brought into contact with the endless belt. Consequently,irregular curing occurs. As a result, there is a fear that, due tooccurrence of marks in appearance such as sink, intrusion of airbubbles, and the like, provided is a molded product that cannot satisfythe function as the electrophotographic blade member.

Further, in a case of using the raw material composition of thepolyurethane resin formed of the polyurethane composition with the shortcuring time, and injecting the composition into the groove with therecessed sectional shape of the heated molding drum, the curingprogresses before the composition is sandwiched by the endless belt.Thus, there is a fear that a predetermined thickness cannot be obtainedeven when the raw material composition of the polyurethane resin, inwhich the curing has progressed, is sandwiched by the endless belt (forexample, see Japanese Patent No. 2645980).

Further, as another conventional method for continuously molding a sheetusing the polyurethane resin, the following is given. Specifically, asthe apparatus for continuously molding the sheet by the molding drum andthe endless belt, the molding drum having a molding surface formed overan entire periphery of the outer peripheral surface, the endless beltbeing brought into press contact with a part of the outer peripheralsurface of the molding drum, there is described a thermosettingelastomer continuos molding apparatus, in which pressurizing isperformed by a back pressure roll from the back surface of the endlessbelt. In this technology, continuous pressurizing is performed and apressurizing force is large, and hence the continuos molding apparatusinvolving no pressure nonuniformity can be provided, with the resultthat intrusion of air bubbles into the molded product can be prevented.

In this method, the back pressure roll is provided on the back surfaceof the endless belt, and intrusion of air bubbles is prevented by highload tension of the endless belt, with the result that the configurationof the apparatus is complex. Thus, an increase in size of the apparatus,an increase in cost of the apparatus, and complexity of setting andadjusting of the apparatus are problems to be solved (for example, seeJapanese Patent Application Laid-Open No. H10-15967).

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a production methodand a production apparatus, for continuously molding a high-qualityelectrophotographic blade member having less irregularities of physicalproperties such as hardness and exhibiting less occurrence of marks inappearance and less occurrence of intrusion of air bubbles, by using apolyurethane resin including a polyurethane composition for a shortcuring time.

In addition, it is another object of the present invention to provide aproduction method and a production apparatus that are capable ofcontinuously producing a high-quality electrophotographic blade memberusing a polyurethane resin including a polyurethane composition for ashort curing time, exhibiting high production efficiency, andcontributing to reducing facility cost, the production apparatus havingsuch a structure as easily realizing automation.

The object is achieved by a method of producing an electrophotographicblade member according to the present invention, including: a mixing andstirring step; an injection step; a thermosetting step; a releasingstep; and a cutting step, the method using a molding drum including acontinuous molding groove in an outer peripheral surface and an endlessbelt brought into contact with a part of the outer peripheral surface ofthe molding drum, in which: the electrophotographic blade member is madeof a polyurethane resin, which is obtained by thermosetting apolyurethane composition containing at least the followings (A) to (D);the polyurethane composition has a viscosity of 500 mPa·s or more and3,000 mPa·s or less after completion of the mixing and stirring step andbefore the injection step; and in the injection step, an arrangementposition of the polyurethane composition is set, on the endless belt, ata position opposing to the molding groove, the position being away froma position at which the molding drum and the endless belt are firstbrought into contact with each other on an upstream side with respect toa moving direction of the endless belt: (A) a polyisocyanate; (B) anadipate-based polyester polyol having a number average molecular weightof 1,000 to 4,000; (C) a chain extender having a molecular weight of 200or less; and (D) an isocyanurate-forming catalyst at 20 ppm or more and500 ppm or less and a urethane-forming catalyst at 200 ppm or more and1,500 ppm or less as curing catalysts.

According to the present invention, it is possible to provide theproduction method and the production apparatus, for continuously moldinga high-quality electrophotographic blade member having lessirregularities of physical properties such as hardness and exhibitingless occurrence of marks in appearance and less occurrence of intrusionof air bubbles, by using a polyurethane resin including a polyurethanecomposition for a short curing time.

In addition, it is also possible to provide the production method andthe production apparatus that are capable of continuously producing ahigh-quality electrophotographic blade member using a polyurethane resinincluding a polyurethane composition for a short curing time, exhibitinghigh production efficiency, and contributing to reducing facility cost,the production apparatus having such a structure as easily realizingautomation.

Further features of the present invention will become apparent from thefollowing description of exemplary embodiments with reference to theattached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view illustrating an example of an apparatus for producingan electrophotographic blade member according to the present invention.

FIG. 2 is a sectional view illustrating an example of a part of a spacesurrounded by a molding groove of a molding drum and an endless belt inthe apparatus for producing an electrophotographic blade memberaccording to the present invention.

FIG. 3A is a sectional view illustrating an example of a part of themolding groove (rectangular shape) formed in the molding drum in theapparatus for producing an electrophotographic blade member according tothe present invention.

FIG. 3B is a sectional view illustrating an example of a part of themolding groove (trapezoid shape) formed in the molding drum in theapparatus for producing an electrophotographic blade member according tothe present invention.

DESCRIPTION OF THE EMBODIMENTS

Hereinafter, the present invention is described in detail.

A method of producing an electrophotographic blade member according tothe present invention includes: a mixing and stirring step; an injectionstep; a thermosetting step; a releasing step; and a cutting step, themethod using a molding drum including a continuous molding groove in anouter peripheral surface and an endless belt brought into contact with apart of the outer peripheral surface of the molding drum, in which: theelectrophotographic blade member is made of a polyurethane resin, whichis obtained by thermosetting a polyurethane composition containing atleast the followings (A) to (D); the polyurethane composition has aviscosity of 500 mPa·s or more and 3,000 mPa·s or less after completionof the mixing and stirring step and before the injection step; and inthe injection step, an arrangement position of the polyurethanecomposition is set, on the endless belt, at a position opposing to themolding groove, the position being away from a position at which themolding drum and the endless belt are first brought into contact witheach other on an upstream side with respect to a moving direction of theendless belt: (A) a polyisocyanate; (B) an adipate-based polyesterpolyol having a number average molecular weight of 1,000 to 4,000; (C) achain extender having a molecular weight of 200 or less; and (D) anisocyanurate-forming catalyst at 20 ppm or more and 500 ppm or less anda urethane-forming catalyst at 200 ppm or more and 1,500 ppm or less ascuring catalysts.

[Basic Configuration of Electrophotographic Blade]

An electrophotographic blade according to the present invention is ablade used as a cleaning blade, a developing blade, or the like for anelectrophotographic apparatus such as a copier, a laser beam printer, anLED printer and apparatus where an electrophotographic technology isapplied, such as electrophotographic plate making systems. The blade hasa configuration in which an electrophotographic blade member formed froma polyurethane resin produced by using a polyurethane composition and asupporting member are bonded. The shapes of the supporting member, theelectrophotographic blade member, and the like are not particularlylimited, and any shape suitable for their intended purposes may only beadopted.

Further, materials for forming the supporting member are notparticularly limited, and the supporting member can be produced frommetal and resin, more specifically, from a metal material such as asteel plate, a stainless steel plate, a zinc-plated steel plate with achromate film, and a chromium-free steel plate and a resin material suchas nylon 6 and nylon 6,6. A method of bonding a supporting member and anelectrophotographic blade member is not particularly limited, and anymethod suitable for their bonding may only be selected from knownmethods.

[Polyurethane Composition]

(Polyisocyanate (A))

Examples of the polyisocyanate (A) to be blended into theabove-mentioned polyurethane composition include 4,4′-diphenylmethanediisocyanate (4,4′-MDI), isophorone diisocyanate (IPDI),4,4′-dicyclohexylmethane diisocyanate (hydrogenated MDI),trimethylhexamethylene diisocyanate (TMHDI), tolylene diisocyanate(TDI), carbodiimide-modified MDI, polymethylene phenyl polyisocyanate(PAPI), ortho-toluidine diisocyanate (TODI), naphthylene diisocyanate(NDI), xylene diisocyanate (XDI), hexamethylene diisocyanate (HMDI),para-phenylene diisocyanate (PDI), lysine diisocyanate methyl ester(LDI), and dimethyl diisocyanate (DDI). Of those, 4,4′-MDI is preferablyused. Those polyisocyanates may be used alone or as a mixture of two ormore kinds thereof.

(Adipate-Based Polyester Polyol (B))

Specific examples of the polyol (B) to be blended into theabove-mentioned polyurethane composition include adipate-basedpolyesters such as polyethylene adipate ester polyol, polybutyleneadipate ester polyol, polyhexylene adipate ester polyol,polyethylene-propylene adipate ester polyol, polyethylene-butyleneadipate ester polyol, and polyethylene-neopentylene adipate esterpolyol. Those polyols may be used alone or as a mixture of two or morekinds thereof.

The polyol (B) to be blended into the above-mentioned polyurethanecomposition is a polyol having a number average molecular weight of1,000 to 4,000. It is not preferred to use a polyol having a numberaverage molecular weight of less than 1,000 as the polyol (B), becausethe number average molecular weight in total of the polyols becomessmaller, and hence the physical properties of the polyurethane resin tobe obtained tend to be low. On the other hand, a polyol having a numberaverage molecular weight of more than 4,000 is not preferred, becausesink marks on the surface of an electrophotographic blade member andcuring irregularities are apt to occur easily.

(Chain Extender (C))

As the chain extender (C) to be blended into the above-mentionedpolyurethane composition, for example, a glycol is used. Examples ofsuch glycol include ethylene glycol (EG), diethylene glycol (DEG),propylene glycol (PG), dipropylene glycol (DPG), 1,4-butanediol(1,4-BD), hexanediol (HD), 1,4-cyclohexanediol,1,4-cyclohexanedimethanol, p-xylylene glycol (terephthalyl alcohol), andtriethylene glycol. Alternatively, other polyhydric alcohols other thanthe above-mentioned glycols may also be used. Examples of suchpolyhydric alcohol include trimethylolpropane, glycerin,pentaerythritol, and sorbitol. Those polyhydric alcohols may be usedalone or as a mixture of two or more kinds thereof.

A chain extender having a molecular weight of 200 or less is used as thechain extender (C). When the molecular weight of the chain extender (C)exceeds 200, aggregation of hard segments occurs less and physicalproperties of the resin to be obtained decreases. As a result,characteristics necessary as an electrophotographic blade member may notbe provided.

(Isocyanurate-Forming Catalyst and Urethane-Forming Catalyst (D))

Curing catalysts (D) to be blended into the above-mentioned polyurethanecomposition include an isocyanurate-forming catalyst at 20 ppm or moreand 500 ppm or less, and a urethane-forming catalyst at 200 ppm or moreand 1,500 ppm or less. Note that ppm is based on mass in the presentinvention.

An isocyanurate-forming catalyst is used to realize the reduction in thereaction and curing time of a polyurethane composition, enabling thereduction in size of a molding apparatus, the reduction in cost of theapparatus, and the improvement in production efficiency of theapparatus. Further, an isocyanurate-forming catalyst provides apolyurethane composition with sensitivity to temperature. As a result,the reaction of the polyurethane composition is delayed at roomtemperature, and heating the polyurethane composition promotes curing,resulting in the progress of an efficient curing reaction. Besides,combined use of a urethane-forming catalyst can yield a urethane resinthat has characteristics necessary as an electrophotographic blademember.

When the content of an isocyanurate-forming catalyst is less than 20ppm, it takes a long time for a polyurethane composition to cure,leading to the increase in size of an apparatus and the increase in costof the apparatus. On the other hand, when the content of anisocyanurate-forming catalyst is more than 500 ppm, a polyurethanecomposition starts curing while the polyurethane composition is mixedand stirred. As a result, a discharging outlet for a polyurethanecomposition is contaminated, causing harm such as intrusion of foreignmatter and occurrence of marks, which are not suitable for anelectrophotographic blade member. Besides, the curing reaction of thepolyurethane composition becomes faster, and hence the polyurethanecomposition may not spread sufficiently in a molding groove after itsinjection, probably resulting in the occurrence of a molding defect orthe like. It is preferred that the content of an isocyanurate-formingcatalyst in a polyurethane composition be 50 ppm or more and 300 ppm orless.

In addition, when the content of a urethane-forming catalyst is lessthan 200 ppm, the rate of a urethane-forming reaction accounting for allreactions in a polyurethane composition decreases. As a result, physicalproperties necessary as an electrophotographic blade member are notprovided. Besides, an irregular reaction occurs, resulting in occurrenceof marks on the surface. When the content of a urethane-forming catalystis more than 1,500 ppm, a polyurethane composition starts curing whilethe polyurethane composition is mixed and stirred. As a result, adischarging outlet is contaminated by the polyurethane composition,causing harm such as intrusion of foreign matter and occurrence ofmarks, which are not suitable for an electrophotographic blade member.It is more preferred that the content of a urethane-forming catalyst ina polyurethane composition be 300 ppm or more and 1,000 ppm or less.

Examples of the isocyanurate-forming catalyst include tertiary aminessuch as N-ethylpiperidine, N,N′-dimethylpiperazine, andN-ethylmorpholine. Further examples include one kind or a mixture of:hydroxides and organic weak acid salts of tetraalkylammoniums such astetramethylammonium, tetraethylammonium, and tetrabutylammonium;hydroxides and organic weak acid salts of hydroxyalkylammoniums such astrimethylhydroxypropylammonium and triethylhydroxypropylammonium; andmetal salts of carboxylic acids such as acetic acid, propionic acid,butyric acid, caproic acid, capric acid, valeric acid, octylic acid,myristic acid, and naphthenic acid. Of those, preferred are metal saltsof carboxylic acids, which have property of starting a curing reactionby heating, that is, sensitivity to temperature, and do not affect otherparts by blooming after molding. Those catalysts may be used alone or asa mixture of two or more kinds thereof.

In addition, a generally used catalyst for polyurethane hardening may beused as the urethane-forming catalyst, and examples thereof include atertiary amine catalyst. Such catalyst is further exemplified by: aminoalcohols such as dimethylethanolamine; trialkylamines such astriethylamine; tetraalkyldiamines such asN,N,N′,N′-tetramethyl-1,3-butanediamine; triethylenediamine;piperazine-based catalysts; and triadine-based catalysts. Alternatively,a metal catalyst which can be typically used for urethane may also beused, and is exemplified by dibutyltin dilaurate or the like. Thosecatalysts may be used alone or as a mixture of two or more kindsthereof.

(Viscosity)

Further, a polyurethane composition has a viscosity of 500 mPa·s or moreand 3,000 mPa·s or less after completion of mixing and stirring andbefore injection.

When a polyurethane composition having a viscosity of less than 500mPa·s is arranged on an endless belt, its liquidity as a polyurethanecomposition is too high. Thus, the polyurethane composition flows andspreads on the endless belt. As a result, even if the polyurethanecomposition is brought into contact with a molding drum later, thepolyurethane composition cannot fill the molding groove of the moldingdrum, and hence the blade member to be obtained is not provided with asize and thickness necessary as an electrophotographic blade member. Onthe other hand, as a polyurethane composition having a viscosity of morethan 3,000 mPa·s has too low a viscosity, the polyurethane compositiondoes not spread over in the molding groove. As a result, the blademember to be obtained is not provided with a size and thicknessnecessary as an electrophotographic blade member, either. From theviewpoints of flowability on an endless belt and filling property in amolding drum, it is more favorable that a polyurethane composition has aviscosity of 800 mPa·s or more and 2,000 mPa·s or less after thepolyurethane composition is mixed and stirred.

(Polyol (E))

As a chain extender (C) having a molecular weight of 200 or less and apolyol (B) having a number average molecular weight of 1,000 to 4,000,which are different in molecular weight, are caused to react with apolyisocyanate (A), the reaction may become nonuniform in theabove-mentioned polyurethane composition. As a result of the nonuniformreaction, irregular curing or the like may cause surface marks.

Thus, it is more preferred that the above-mentioned polyurethanecomposition contain a polyol (E) having a number average molecularweight which is smaller than the number average molecular weight of thepolyol (B) and larger than the molecular weight of the chain extender(C). By introducing the polyol (E) having a number average molecularweight between the number average molecular weight of the polyol (B) andthe molecular weight of the chain extender (C), the difference in themolecular weight of these compounds varies in a multistep manner. As aresult, even in the case where a more rapid reaction occurs by using acatalyst having a good sensitivity to temperature, it is possible toobtain an electrophotographic blade member in which occurrence ofsurface marks derived from irregular shrinkage is suppressed.

Examples of the above-mentioned polyol (E) include polyesters such aspolyethylene adipate ester polyol, polybutylene adipate ester polyol,polyhexylene adipate ester polyol, polyethylene-propylene adipate esterpolyol, polyethylene-butylene adipate ester polyol, andpolyethylene-neopentylene adipate ester polyol. Those polyols may beused alone or as a mixture of two or more kinds thereof. Alternatively,polyethers such as polyethylene glycol, polypropylene glycol, andpolytetramethylene glycol may be used. Those polyethers may be usedalone or as a mixture of two or more kinds thereof.

(Ratio of Polyol (E) to Adipate-Based Polyester Polyol (B) and MolecularWeight of their Mixture)

It is preferred that (E)/(B), which is the mass ratio of a polyol (E) toa polyol (B), both being contained in a polyurethane composition, fall0.02 to 0.60. When the mass ratio is set to 0.02 or more, the polyol (E)can contribute to efficiently making the difference in molecular weightbetween a chain extender (C) and the polyol (B) a multistep difference,and hence the effect of suppressing surface marks caused by irregularshrinkage is more improved. On the other hand, when the mass ratio isset to 0.60 or less, the content ratio of the polyol (E) having asmaller number average molecular weight than the polyol (B) is suitable,and hence the polyurethane resin to be obtained tends to have moresuitable physical properties as an electrophotographic blade member.

In addition, it is preferred that the number average molecular weight intotal of the above-mentioned polyol (B) and the above-mentioned polyol(E) fall 1,000 to 3,000. When the number average molecular weight is1,000 or more, the polyurethane resin to be obtained has more suitablephysical properties as an electrophotographic blade member. Further,when the number average molecular weight is 3,000 or less, the viscosityof a prepolymer becomes lower, resulting in the improvement in theflowability of the prepolymer into a space formed by a molding groove ofa molding drum and an endless belt.

[Method and Apparatus for Producing Electrophotographic Blade Member]

Hereinafter, a production method and a production apparatus according toan embodiment of the present invention are described with reference tothe drawings. FIG. 1 is a schematic view illustrating an example of theapparatus for producing an electrophotographic blade member.

(Measuring, Mixing, and Stirring)

First, a polyurethane composition is measured, mixed, and stirred, tothereby prepare the mixture. As illustrated in FIG. 1, an apparatus formixing and stirring the polyurethane composition includes at least twotanks 10 and 11. Further, outlets of the respective tanks are connectedto a mixing head 16 through measuring pumps 12 and 13, and the mixinghead 16 and the tanks 10, 11 are connected to each other throughdischarge/circulation pipes 14 and 15. In addition, the mixing head 16has known structure in which a stirring rotator is provided in a chamberincluding an inlet and an outlet for a liquid, and can discharge thepolyurethane composition with high accuracy. By using such aquantitative mixer, a certain amount of the polyurethane composition issupplied to the mixing head by the measuring pumps, and mixed andstirred uniformly.

(Injecting)

Next, a molding apparatus has a configuration in which a molding drum 18and an endless belt 19 are provided. The molding drum 18 has acontinuous molding groove for the electrophotographic blade memberformed in its outer peripheral surface in a rotating direction, and theendless belt 19 is arranged so as to cover the molding groove at a partof the outer peripheral surface of the molding drum 18. Further, themolding apparatus includes heating means which is arranged to beembedded in the molding drum 18 or close to the molding drum 18, or tobe intimate contact with or close to the endless belt 19 side of aportion at which the molding drum 18 and the endless belt 19 are broughtinto press contact with each other. The polyurethane compositioninjected into the molding groove can be subjected to thermosetting bythe heating means within a space portion 23 surrounded by the moldinggroove on the molding drum 18 and the endless belt 19 as illustrated inFIG. 2.

The molding drum 18 is made of, for example, hard aluminum, iron, andstainless steel. A center portion of the molding drum is rotatablysupported by a horizontal rotation shaft 17, and the molding drum isrotated at a predetermined speed by a drive device.

The shape of the molding groove formed continuously in the outerperipheral surface of the molding drum 18 is selected as needed inconformity with the shape of the electrophotographic blade member to beproduced. For example, the molding groove may have a rectangular shapein cross-section as illustrated in FIG. 3A, and a trapezoid shape incross-section as illustrated in FIG. 3B.

Further, the endless belt 19 is formed of, for example, a metal stripmade of stainless steel or the like. A resin belt or the like made ofother than stainless steel can implement a mechanism, but it ispreferred that means capable of heating from the outer side of the resinbelt be used at that time.

The endless belt 19 is wound around a driving roll 20 having a drivemechanism different from that for the molding drum 18, guide rolls 21for regulating running of the endless belt, and a tension roll 22 forapplying tension to the endless belt 19. The molding drum 18 and theendless belt 19 are rotated at the same peripheral speed.

Further, it is preferred that the molding drum 18 and the endless belt19 have different drive means, because it is possible to reduce thetension of the endless belt 19. The drive means may be implemented bycombination of, for example, a motor, a clutch, and a brake. However, itis preferred that, in order to make the molding drum 18 and the tensionof the endless belt 19 constant according to the peripheral speed of themolding drum 18, the molding drum 18 be driven by a motor and theendless belt 19 be driven by a powder brake and a motor. Note that, itis preferred that the peripheral speed of the molding drum 18 and theperipheral speed of the endless belt 19 be set in consideration of adefect of the endless belt 19, marks of a molded product, and the like.

It is preferred that the tension of the tension roll 22 for applyingtension to the endless belt 19 be set to be equal to or lower than thetension, under which the endless belt 19 is pressed against the moldingdrum 18, in consideration of an influence on the tension during drivingof the endless belt 19, a bend of the endless belt 19, and the like.

As a heating method of the heating means, there may be employed aheating method from the outside or the inside of the molding drum 18.Heating from the outside is influenced by disturbance (room temperature,etc.), and hence internal heating in which the molding drum 18 isdirectly heated is preferred. Means such as a heater, oil, and water maybe employed as the means for performing the internal heating, but theheater is most suitable in view of space saving and temperature control.It is desired that heating be performed within a predeterminedtemperature ±5° C. in consideration of appearance abnormality and thelike of a molded product.

In the apparatus illustrated in FIG. 1, the mixing head 16 as a rawmaterial arranging means is provided with the discharging outlet fromwhich the polyurethane composition can be discharged at a predeterminedspeed. The polyurethane composition in the mixing head 16 is dischargedfrom the discharging outlet, to thereby be arranged on the endless belt19. At this time, the molding drum 18 and the endless belt 19 arerotated at the predetermined speed, and a necessary amount correspondingto the space portion (groove) formed by the molding drum 18 and theendless belt 19 is injected continuously. Note that, in the presentinvention, the position of the discharging outlet is referred to as adischarge position.

According to the method of the present invention, the polyurethanecomposition is arranged, on the endless belt 19, at a position opposedto the molding groove, the position being away from a position at whichthe molding drum 18 and the endless belt 19 are first brought intocontact with each other on an upstream side with respect to a movingdirection of the endless belt 19. Note that, in the present invention,the above-mentioned position is referred to as an arrangement position.

Here, it is preferred that the discharging outlet position (dischargeposition) of the mixing head 16 of the quantitative mixer be arranged atan upward distance in a vertical direction of 5 mm or more and 200 mm orless from the arrangement position of the polyurethane composition abovethe endless belt 19. When the distance is less than 5 mm, thedischarging outlet is likely to be brought into contact with thedischarged polyurethane composition, and thus the discharging outlet maybe contaminated. Consequently, there is a fear that foreign matterintrudes into the injected polyurethane composition, with the resultthat it may be impossible to obtain the electrophotographic blade memberwith high quality. When discharged from a position at an upward distanceof more than 200 mm, the polyurethane composition is likely to beinfluenced by the ambient environment such as an air flow around thedischarging outlet, and a discharge liquid fluctuates, for example.Thus, in some cases, the polyurethane composition may be arranged to beshifted from an appropriate position on the endless belt 19corresponding to the molding groove, and air bubbles intrude into thepolyurethane composition.

Further, it is preferred that the arrangement position of thepolyurethane composition be set, on the endless belt 19, at a positionopposing to the molding groove, the position being 5 mm or more and 350mm or less away from the position at which the molding drum 18 and theendless belt 19 are first brought into contact with each other on theupstream side with respect to the moving direction of the endless belt19. When the above-mentioned position is at a distance of less than 5mm, in the discharged polyurethane composition, intrusion of air bubblesat the time of injection and nonuniform injection occur, and hence thedesired electrophotographic blade member cannot be obtained in somecases. Further, when the distance is larger than 350 mm, the dischargedpolyurethane composition flows and spreads beyond the width of the spaceportion (groove), with the result that the desired size (thickness) ofthe electrophotographic blade member cannot be obtained in some cases.The arrangement position of the present invention is adjusted to theposition opposed to the molding groove on the endless belt 19, and anadjusting method may be selected from known art such as a cylinder, a NC(numerical control), and a mechanical stopper.

The curing reaction of the polyurethane composition according to thepresent invention is accelerated by heating. However, the polyurethanecomposition is injected onto the endless belt 19 having no heatingmechanism, and hence the urethane polymer reaction accelerated by heatdoes not progress. After the endless belt 19 is brought into contactwith the heated molding drum, the temperature of the contact surfacethereof rises promptly, and the polyurethane composition injected ontothe endless belt 19 moves and fills the molding groove on the moldingdrum 18 to be heated and pressurized, with the result that the urethanepolymer reaction is started. In this way, it is possible to cure thepolyurethane composition uniformly without irregularities. When thepolyurethane composition is injected into the groove portion on themolding drum 18, the curing progresses from a surface that is firstbrought into contact with the groove portion, and hence the curingprogresses only at a surface brought into contact with the heatedmolding drum 18 ahead of other portions, and thus there occurs surfacemarks and nonuniformity of physical properties caused by irregularcuring of the surface brought into contact with the endless belt 19. Acooling mechanism for cooling the endless belt 19 may be provided to aportion that is not brought into contact with the molding drum 18.

(Curing)

Next, the polyurethane composition is subjected to thermosetting for apredetermined period of time while caused to fill the space portion 23formed by the molding groove of the molding drum 18 and the endless belt19. In this way, the urethane polymer reaction of the polyurethanecomposition is completed to such an extent that the polyurethanecomposition is releasable from the molding drum 18 and the endless belt19, and a prototype of the electrophotographic blade member having anecessary width, thickness, and surface property is formed continuously.Note that, in the embodiment employing the production apparatusillustrated in FIG. 1, it is preferred that the heating temperaturerange from approximately 80° C. to 200° C., and it takes 20 seconds to90 seconds for the polyurethane composition to be releasable from themolding drum 18 and the endless belt 19 by development of the urethanepolymer reaction. However, if the curing is finished to such an extentthat the polyurethane composition is releasable from the molding drum 18and the endless belt 19, it is possible to perform releasing, and henceit is possible to select the heating temperature and heating time asneeded according to the composition of the polyurethane composition andthe configuration of the production apparatus.

(Releasing and Cutting)

The polyurethane resin thus subjected to thermosetting is released fromthe molding drum 18 and the endless belt 19 by releasing means 24.

The released polyurethane resin is conveyed by a conveying mechanism 25,and cut into a predetermined dimension by a cutting mechanism 26. Asuitable known method, such as punching and NC cutting using a cutter,may be selected as the cutting method.

(Releasing Treatment)

It is desired that at least a portion of the molding drum 18 with whichthe polyurethane composition is brought into contact, for example, themolding groove be subjected to the releasing treatment. The releasingtreatment includes a method for applying a release agent on a surface ofa die using a release-agent treatment device or the like, a method forapplying plating, such as plating containing polytetrafluoroethylene(PTFE) or fluorine, on the surface of the molding drum 18, a method forcoating a releasable resin such as silicon, and the like. However, aslong as a polyurethane resin releasable, a suitable method may beselected.

Further, it is also desired that at least a portion of the endless belt19 with which the polyurethane composition is brought into contact besubjected to the releasing treatment. As a method of the releasingtreatment, there may be employed a method similar to the releasingtreatment performed on the molding drum 18.

(Roughing Treatment)

When the electrophotographic blade member according to the presentinvention is used for a developer amount regulating blade, it is desiredthat, at least at a portion of the electrophotographic blade member,which is brought into contact with a developer carrier, a rough surfaceportion be formed at the portion of the electrophotographic blade memberthat comes into contact therewith. Note that, the developer amountregulating blade serves as a blade for uniformly regulating an amount ofdeveloper in the form of a thin layer while the developer isfrictionally charged between the developer carrier and the blade in anelectrophotographic apparatus.

In recent years, the electrophotographic process has been advanced toprovide higher image quality and higher speed, and hence it is importanthow the developer amount regulating blade uniformly charges and conveysdeveloper particles. In particular, the surface property of thedeveloper amount regulating blade is especially important because thesurface property thereof greatly affects both a conveying force for thedeveloper and a charge amount. Conventionally, it has been consideredthat, in order to uniformly charge and convey the developer particles,the smoother charge control surface of the developer amount regulatingblade is the better. However, in recent years, when specificallystudying the influence of the evenness of the charge control surface onuniform charge and conveyance of the developer, it has been found thatroughing a developer control surface to some extent can realize theuniform charge and conveyance of the developer, and suppress imagedefects such as image streaks and image unevenness. Therefore, it ispreferred that the rough surface portion be formed at least one cornerof a bottom surface in cross-section orthogonal to a longitudinaldirection of the molding groove of the molding drum 18 according to thepresent invention. With this configuration, when the electrophotographicblade member is used for the developer amount regulating blade, at leastthe portion that is brought into contact with the developer carrier isroughed, and hence it is possible to realize the uniform charge andconveyance of the developer.

Examples of a method for forming the rough surface portion include amethod for roughing by a physical method. Specific examples of thephysical method include a method for roughing the surface of the moldingdrum 18 by using sandpaper and a roughing film, a method for providingthe rough surface portion in the molding groove, and a shot blastingmethod such as a sand blasting method. Further, roughing can beperformed by a chemical method. Specific examples of the chemical methodmay include an etching method and a method for forming a layercontaining roughed fine particles. It is preferred that the level ofroughness range approximately from 2 μm to 25 μm in ten point height ofirregularities (RzJIS).

EXAMPLES

The present invention is described based on the following examples, butthe present invention is by no means limited by those examples.

Example 1 PBA2000

(Preparation of Thermosetting Polyurethane Composition)

32.0 parts by mass of 4,4′-diphenylmethane diisocyanate (MDI) and 61.0parts by mass of polybutylene adipate polyester polyol (PBA) having amolecular weight of 2,000 were caused to react for 3 hours under an 80°C. nitrogen atmosphere, yielding a prepolymer containing NCO at 8.8%. Onthe other hand, 3.9 parts by mass of 1,4-butanediol (1,4-BD), 3.2 partsby mass of trimethylolpropane (TMP), and a urethane-curing catalyst weremixed, yielding a curing agent. An isocyanurate-forming catalyst and aurethane-forming catalyst were used as curing catalysts. There was used,as a polyurethane-curing catalyst, an isocyanurate-forming catalyst withthe product name of “P15” (a potassium acetate solution in ethyleneglycol (EG), produced by Air Products Japan, Inc.). In this case, theisocyanurate-forming catalyst was blended so as to account for 80 ppm ofthe resultant polyurethane composition. Further, there was used, as aurethane-forming catalyst, triethylenediamine (product name “DABCOcrystal”; produced by Air Products Japan, Inc.). The content of theurethane-forming catalyst was adjusted so that the urethane-formingcatalyst accounts for 340 ppm of the resultant polyurethane composition.

Note that there was used, as MDI, a product with the name of “MillionateMT” (produced by Nippon Polyurethane Industry Co., Ltd.). There wasused, as PBA having a molecular weight of 2,000, a product with the nameof “NIPPOLLAN 4010” (produced by Nippon Polyurethane Industry Co.,Ltd.). There was used 1,4-BD produced by Mitsubishi ChemicalCorporation. There was used TMP produced by Mitsubishi Gas ChemicalCompany, Inc.

The molecular weight of PBA was calculated based on the followingmathematical formula. Further, the hydroxyl group value in the formulawas calculated according to JIS-K1557-1.

Molecular weight=1,000/Hydroxyl group value×The number of functionalgroups×56.11  [Math. 1]

In this example, the production apparatus illustrated in FIG. 1 was usedto produce an electrophotographic blade member. The prepolymer and thecuring agent were fed into the tanks 10 and 11, respectively, and weresupplied into the mixing head 16 while being measured with measuringpumps 12 and 13, respectively. The prepolymer and the curing agent wereuniformly stirred and mixed in the mixing head 16, thereby preparing apolyurethane composition. Table 1 shows the viscosity of thepolyurethane composition at this time.

The molding drum 18, which is made of stainless steel, is rotatablysupported by the rotation shaft 17 to be positioned approximatelyhorizontally. The molding drum 18 of the molding apparatus has, in therotating direction, a continuous molding groove having a width of 20 mmand a depth of 1 mm, the groove serving as an original mold for anelectrophotographic blade member, and the outer peripheral portion ofthe molding drum 18 has been subjected to fluoride plating treatment. Inthis example, the molding drum 18 was rotated at 1.5 rpm by a drivedevice.

The endless belt 19, which is made of metal, is arranged so as to coverthe molding groove of the molding drum 18. Fluoride plating treatmenthas been performed on the portion with which a polyurethane compositionof the endless belt 19 is brought into contact. The endless belt 19 iswound around the driving roll 20 having a drive mechanism different fromthat for the molding drum 18, the guide rolls 21 for regulating therunning of the endless belt, and the tension roll 22 for applyingtension to the endless belt. Further, the endless belt 19 was rotated soas to match the peripheral speed of the molding drum 18.

The driving for the molding drum 18 and the driving for the endless belt19 were constituted differently. Further, in order to make the wholetension of the endless belt 19 and the molding drum 18 constantaccording to the peripheral speed of the molding drum 18, the moldingdrum 18 was driven by a motor and the endless belt 19 was driven by apowder brake and a motor.

The arrangement position of a polyurethane composition was set, on theendless belt 19, to the position opposed to a molding groove, theposition being 5 mm away from the portion at which the molding drum 18and the endless belt 19 were first brought into contact with each otheron the upstream side with respect to the moving direction of the endlessbelt 19. Further, the discharge position of a polyurethane compositionwas set to the position 5 mm above the arrangement position in thevertical direction.

A polyurethane composition injected into the molding groove of themolding drum 18 was subjected to thermosetting for a predeterminedperiod of time (40 seconds) by adjusting the temperature of the moldinggroove to 135° C. with a cartridge heater built in the molding drum 18.After that, the cured product was released and cut into a piece having apredetermined size by using a punching die with a Thomson blade, tothereby yield an electrophotographic blade member having a thickness of1 mm.

The electrophotographic blade member thus obtained and anelectrogalvanizing steel plate, ZINKOTE 21 (product name: produced byNIPPON STEEL CORPORATION), having a chromium-free surface treatmentlayer containing an urethane-modified olefin resin and anacrylic-modified olefin resin as a supporting member were bonded byheating using a film-shaped hot melt adhesive, Elphan UH (product name:produced by Nihon Matai Co., Ltd.), as an adhesive, to thereby yield adeveloper amount regulating blade.

The developer amount regulating blade thus obtained was evaluated forrubber hardness, rubber hardness difference, surface mark caused byirregular curing, intrusion of air bubble and foreign matter, and imagesby using the following methods. Table 1 shows the results of theevaluation.

(Viscosity)

The viscosity of the polyurethane composition was measured under ameasurement environment of 25° C. by using an “SV type viscometer” SV-10produced by A & D Company, Ltd.

(Measurement of Rubber Hardness and Rubber Hardness Difference)

International Rubber Hardness Degree (IRHD) was measured by usingWallace Microhardness Tester produced by Wallace Instruments (H. W.WALLACE), based on JIS K 6253. An original product of the moldedelectrophotographic blade member was measured at 5 points with each 500mm distance. The average value of the resultant values was shown as therubber hardness and the difference between the maximum value and theminimum value was shown as the hardness difference.

(Curing Irregularity of Surface)

The curing irregularity of the surface of the electrophotographic blademember was checked by visual observation, and the results were evaluatedbased on the following criteria.

A: No surface mark is present.B: Surface marks distinguishable in appearance are present.C: Surface marks having such a level as causing image defects arepresent.

(Intrusion of Air Bubble and Foreign Matter)

Intrusion of air bubbles and intrusion of foreign matter in the surfaceof the electrophotographic blade member were each checked by visualobservation, and the results were evaluated based on the followingcriteria.

A: No intrusion of air bubbles and foreign matter is present.C: Intrusion of air bubbles and foreign matter is present.

(Image Evaluation)

The produced developer amount regulating blade was incorporated into acartridge for a “LASER SHOT-LBP” (product name, produced by Canon Inc.),and a ghost and image streaks were evaluated based on the followingcriteria.

Ghost

A: No ghost is present.B: A ghost is slightly confirmed.C: A ghost is clearly confirmed.

Image streak

A: No image streak is present.B: Image streaks are confirmed as a slight change on an image.C: Image streaks are confirmed as a great change on an image.

Example 2 PBA2000 and PBA1000

27.7 parts by mass of 4,4′-diphenylmethane diisocyanate (MDI) and 52.7parts by mass of polybutylene adipate polyester polyol (PBA) having amolecular weight of 2,000 were caused to react for 3 hours under an 80°C. nitrogen atmosphere, yielding a prepolymer containing NCO at 8.8%. Onthe other hand, 14.9 parts by mass of PBA having a molecular weight of1,000 (product name “NIPPOLLAN 4009” (produced by Nippon PolyurethaneIndustry Co., Ltd.)), 2.6 parts by mass of 1,4-butanediol (1,4-BD), 2.1parts by mass of trimethylolpropane (TMP), and the same curing catalystsas those used in Example 1 were mixed, yielding a curing agent. Thecuring catalysts were contained at the same ratios as those inExample 1. The thus obtained polyurethane composition was subjected tothe same processes as those in Example 1, to thereby produce a developeramount regulating blade. The developer amount regulating blade wasevaluated in the same manner as that in Example 1. Table 1 shows theresults of the evaluation.

Note that Table 1 shows the values of (E)/(B), which is the mass ratioof polybutylene adipate polyester polyol (PBA) having a number averagemolecular weight of 1,000 corresponding to the polyol (E) topolybutylene adipate polyester polyol (PBA) having a number averagemolecular weight of 2,000 corresponding to the polyol (B) in thepolyurethane composition, and also shows the number average molecularweight in total of the above-mentioned polyols.

Example 3 PEA2000

A developer amount regulating blade was produced in the same manner asthat in Example 1, except that polyethylene adipate polyol (PEA) havinga number average molecular weight of 2,000 (product name “NIPPOLLAN4040” (produced by Nippon Polyurethane Industry Co., Ltd.)) was used asthe polyol (B), and the feeding amounts were changed to those listed inTable 1. Further, evaluation was performed in the same manner as that inExample 1. Table 1 shows the results of the evaluation.

Example 4

A developer amount regulating blade was produced and evaluated in thesame manner as that in Example 1, except that a material aspreliminarily produced polybutylene adipate polyester polyol (PBA)having a number average molecular weight of 4,000 was used as the polyol(B), and the feeding amounts were changed to those listed in Table 1.Table 1 shows the results of the evaluation.

Example 5

A developer amount regulating blade was produced in the same manner asthat in Example 1, except that polybutylene adipate polyester polyol(PBA) having a number average molecular weight of 1,000 (product name“NIPPOLLAN 4009” (produced by Nippon Polyurethane Industry Co., Ltd.))was used as the polyol (B), and the feeding amounts were changed tothose listed in Table 1. Further, evaluation was performed in the samemanner as that in Example 1. Table 1 shows the results of theevaluation.

Example 6 Viscosity: 500 mPa·s

35.9 parts by mass of 4,4′-diphenylmethane diisocyanate (MDI) and 34.7parts by mass of polybutylene adipate polyester polyol (PBA) having amolecular weight of 2,000 were caused to react for 3 hours under an 80°C. nitrogen atmosphere, yielding a prepolymer containing NCO at 15%. Onthe other hand, 22.3 parts by mass of PBA having a molecular weight of1,000, 3.9 parts by mass of 1,4-butanediol (1,4-BD), 3.2 parts by massof trimethylolpropane (TMP), and the same curing catalysts as those usedin Example 1 were mixed, yielding a curing agent. The curing catalystswere contained at the same ratios as those in Example 1. The mixedpolyurethane composition had a viscosity of 500 mPa·s.

The same subsequent process as that in Example 1 was carried out, tothereby produce and evaluate a developer amount regulating blade. Table1 shows the results of the evaluation.

Example 7 Viscosity: 3,000 mPa·s

21.4 parts by mass of 4,4′-diphenylmethane diisocyanate (MDI) and 66.4parts by mass of polybutylene adipate polyester polyol (PBA) having amolecular weight of 2,000 were caused to react for 3 hours under an 80°C. nitrogen atmosphere, yielding a prepolymer containing NCO at 5%. Onthe other hand, 9.3 parts by mass of PBA having a molecular weight of1,000, 1.6 parts by mass of 1,4-butanediol (1,4-BD), 1.3 parts by massof trimethylolpropane (TMP), and the same curing catalysts as those usedin Example 1 were mixed, yielding a curing agent. The curing catalystswere contained at the same ratios as those in Example 1. The mixedpolyurethane composition had a viscosity of 3,000 mPa·s.

The same subsequent process as that in Example 1 was carried out, tothereby produce and evaluate a developer amount regulating blade. Table1 shows the results of the evaluation.

Example 8

In Example 2, the content of the isocyanurate-forming catalyst as apolyurethane-curing catalyst in a polyurethane composition was adjustedto 20 ppm. Further, the content of the urethane-forming catalyst asanother polyurethane-curing catalyst in the polyurethane composition wasadjusted to 200 ppm.

The contents of the other materials in the polyurethane compositionremained the same as those in Example 2, to thereby produce anelectrophotographic blade member. Then, the same subsequent process asthat in Example 1 was carried out on the electrophotographic blademember, thereby yielding a developer amount regulating blade. The thusobtained developer amount regulating blade was evaluated in the samemanner as that in Example 1. Table 1 shows the results of theevaluation.

Example 9

In Example 2, the content of the isocyanurate-forming catalyst as apolyurethane-curing catalyst in the polyurethane composition wasadjusted to 20 ppm. Further, the content of the urethane-formingcatalyst as another polyurethane-curing catalyst in the polyurethanecomposition was adjusted to 1,500 ppm.

The contents of the other materials in the polyurethane compositionremained the same as those in Example 2, to thereby produce anelectrophotographic blade member. Then, the same subsequent process asthat in Example 1 was carried out on the electrophotographic blademember, thereby yielding a developer amount regulating blade. The thusobtained developer amount regulating blade was evaluated in the samemanner as that in Example 1. Table 1 shows the results of theevaluation.

Example 10

In Example 2, the content of the isocyanurate-forming catalyst as apolyurethane-curing catalyst in the polyurethane composition wasadjusted to 500 ppm. Further, the content of the urethane-formingcatalyst as another polyurethane-curing catalyst in the polyurethanecomposition was adjusted to 200 ppm.

The contents of the other materials in the polyurethane compositionremained the same as those in Example 2, to thereby produce anelectrophotographic blade member. Then, the same subsequent process asthat in Example 1 was carried out on the electrophotographic blademember, thereby yielding a developer amount regulating blade. The thusobtained developer amount regulating blade was evaluated in the samemanner as that in Example 1. Table 1 shows the results of theevaluation.

Example 11

In Example 2, the content of the isocyanurate-forming catalyst as apolyurethane-curing catalyst in the polyurethane composition wasadjusted to 500 ppm. Further, the content of the urethane-formingcatalyst as another polyurethane-curing catalyst in the polyurethanecomposition was adjusted to 1,500 ppm.

The contents of the other materials in the polyurethane compositionremained the same as those in Example 2, to thereby produce anelectrophotographic blade member. Then, the same subsequent process asthat in Example 1 was carried out on the electrophotographic blademember, thereby yielding a developer amount regulating blade. The thusobtained developer amount regulating blade was evaluated in the samemanner as that in Example 1. Table 1 shows the results of theevaluation.

Comparative Example 1

A developer amount regulating blade was produced and evaluated in thesame manner as that in Example 1, except that polybutylene adipatepolyester polyol (PBA) having a number average molecular weight of 800was used as the polyol (B), and the feeding amounts were changed tothose listed in Table 2. Table 2 shows the results of the evaluation.

Comparative Example 2

A developer amount regulating blade was produced and evaluated in thesame manner as that in Example 1, except that polybutylene adipatepolyester polyol (PBA) having a number average molecular weight of 4,500was used as the polyol (B), and the feeding amounts were changed tothose listed in Table 2. Table 2 shows the results of the evaluation.

Comparative Example 3

41.2 parts by mass of 4,4′-diphenylmethane diisocyanate (MDI) and 23.1parts by mass of polybutylene adipate polyester polyol (PBA) having amolecular weight of 2,000 were caused to react for 3 hours under an 80°C. nitrogen atmosphere, yielding a prepolymer containing NCO at 20%. Onthe other hand, 27.1 parts by mass of PBA having a molecular weight of1,000, 4.7 parts by mass of 1,4-butanediol (1,4-BD), 3.9 parts by massof trimethylolpropane (TMP), and the same curing catalysts as those usedin Example 1 were mixed, yielding a curing agent. The curing catalystswere contained at the same ratios as those in Example 1. The mixedpolyurethane composition had a viscosity of 420 mPa·s.

The same subsequent process as that in Example 1 was carried out, tothereby produce and evaluate a developer amount regulating blade. Table2 shows the results of the evaluation.

Comparative Example 4

21.4 parts by mass of 4,4′-diphenylmethane diisocyanate (MDI) and 66.4parts by mass of polybutylene adipate polyester polyol (PBA) having amolecular weight of 2,000 were caused to react for 3 hours under an 80°C. nitrogen atmosphere, yielding a prepolymer containing NCO at 5%. Onthe other hand, 9.3 parts by mass of PBA having a molecular weight of1,000, 1.6 parts by mass of 1,4-butanediol (1,4-BD), 1.3 parts by massof trimethylolpropane (TMP), and the same curing catalysts as those usedin Example 1 were mixed, yielding a curing agent. The curing catalystswere contained at the same ratios as those in Example 1. The thusobtained materials were fed into a two-liquid measuring, mixing, anddispensing machine. While the materials were uniformly stirred and mixedin a mixing head, the machine was adjusted so that a polyurethanecomposition remained in the mixing head until the polyurethanecomposition had a viscosity of 3,800 mPa·s at the time of its discharge.

The same subsequent process as that in Example 1 was carried out, tothereby produce and evaluate a developer amount regulating blade. Table2 shows the results of the evaluation.

Comparative Example 5

In Example 2, the content of the isocyanurate-forming catalyst as apolyurethane-curing catalyst in the polyurethane composition wasadjusted to 15 ppm. Further, the content of the urethane-formingcatalyst as another polyurethane-curing catalyst in the polyurethanecomposition was adjusted to 180 ppm.

The contents of the other materials in the polyurethane compositionremained the same as those in Example 2, to thereby produce anelectrophotographic blade member. Then, the same subsequent process asthat in Example 1 was carried out on the electrophotographic blademember, thereby yielding a developer amount regulating blade. The thusobtained developer amount regulating blade was evaluated in the samemanner as that in Example 1. Table 2 shows the results of theevaluation.

Comparative Example 6

In Example 2, the content of the isocyanurate-forming catalyst as apolyurethane-curing catalyst in the polyurethane composition wasadjusted to 600 ppm. Further, the content of the urethane-formingcatalyst as another polyurethane-curing catalyst in the polyurethanecomposition was adjusted to 180 ppm.

The contents of the other materials in the polyurethane compositionremained the same as those in Example 2, to thereby produce anelectrophotographic blade member. Then, the same subsequent process asthat in Example 1 was carried out on the electrophotographic blademember, thereby yielding a developer amount regulating blade. The thusobtained developer amount regulating blade was evaluated in the samemanner as that in Example 1. Table 2 shows the results of theevaluation.

Comparative Example 7

In Example 2, the content of the isocyanurate-forming catalyst as apolyurethane-curing catalyst in the polyurethane composition wasadjusted to 15 ppm. Further, the content of the urethane-formingcatalyst as another polyurethane-curing catalyst in the polyurethanecomposition was adjusted to 1,520 ppm.

The contents of the other materials in the polyurethane compositionremained the same as those in Example 2, to thereby produce anelectrophotographic blade member. Then, the same subsequent process asthat in Example 1 was carried out on the electrophotographic blademember, thereby yielding a developer amount regulating blade. The thusobtained developer amount regulating blade was evaluated in the samemanner as that in Example 1. Table 2 shows the results of theevaluation.

Comparative Example 8

In Example 2, the content of the isocyanurate-forming catalyst as apolyurethane-curing catalyst in the polyurethane composition wasadjusted to 600 ppm. Further, the content of the urethane-formingcatalyst as another polyurethane-curing catalyst in the polyurethanecomposition was adjusted to 1,520 ppm.

The contents of the other materials in the polyurethane compositionremained the same as those in Example 2, to thereby produce anelectrophotographic blade member. Then, the same subsequent process asthat in Example 1 was carried out on the electrophotographic blademember, thereby yielding a developer amount regulating blade. The thusobtained developer amount regulating blade was evaluated in the samemanner as that in Example 1. Table 2 shows the results of theevaluation.

Comparative Example 9

The arrangement position of a polyurethane composition prepared in thesame manner as that in Example 2 was set to a summit 27 of the moldingdrum 18 in FIG. 1. The discharge position of the polyurethanecomposition was set to the position 5 mm above the arrangement positionin the vertical direction. The same method as that in Example 1 exceptthe above was carried out to produce a developer amount regulatingblade, followed by evaluation. Table 2 shows the results of theevaluation.

The above-mentioned results show that, in each of the examples, evenwhen a polyurethane composition having a fast curing speed was used,irregularities of physical properties such as hardness decreased,occurrence of marks in appearance and occurrence of intrusion of airbubbles reduced, and image evaluation was good. On the other hand, ineach of the comparative examples, the hardness difference of apolyurethane resin after curing was large, marks caused by irregularcuring occurred on the surface, intrusion of air bubbles and foreignmatter occurred, and image defects occurred.

Note that when the above-mentioned materials other than those used inexamples were used as a polyisocyanate, an adipate-based polyesterpolyol, a chain extender, an isocyanurate-forming catalyst, and aurethane-forming catalyst, the same results as those in examples wereobtained.

Further, a molding drum on which a continuous molding groove having adepth of 2 mm was formed was used to produce each electrophotographicblade member having a thickness of 2 mm in the same manner as that ineach of the examples. The electrophotographic blade member was bonded toa supporting member as in Example 1, to thereby yield a cleaning blade.The resultant cleaning blade was incorporated into a cartridge for a“LASER SHOT-LBP” (product name, produced by Canon Inc.) to check imagestreaks caused by defective cleaning. The results of each example showthat cleaning functions are good and images are good. However, in eachcomparative example, image streaks occurred because edge portions of anelectrophotographic blade member chipped and toner slipped through thebroken edge portions, causing defective cleaning.

TABLE 1 Item Example 1 Example 2 Example 3 Example 4 Example 5 Example 6Preparation of prepolymer Polyisocyanate Type 4,4′-MDI 4,4′-MDI 4,4′-MDI4,4′-MDI 4,4′-MDI 4,4′-MDI (A) Amount (g) 32.0 27.7 32.0 28.4 38.1 35.9Polyol (B) Type PBA PBA PEA PBA PBA PBA Number average 2,000 2,000 2,0004,000 1,000 2,000 molecular weight Amount (g) 61.0 52.7 61.0 64.6 54.934.7 NCO (%) 8.8% 8.8% 8.8% 8.8% 8.8% 15.0% Preparation of curing agentChain extender Type 1,4-BD 1,4-BD 1,4-BD 1,4-BD 1,4-BD 1,4-BD (C) (1)Molecular weight 90.1 90.1 90.1 90.1 90.1 90.1 Amount (g) 3.9 2.6 3.93.9 3.9 3.9 Chain extender Type TMP TMP TMP TMP TMP TMP (C) (2)Molecular weight 134.2 134.2 134.2 134.2 134.2 134.2 Amount (g) 3.2 2.13.2 3.2 3.2 3.2 Polyol (E) Type — PBA — — — PBA Number average — 1,000 —— — 1,000 molecular weight Amount (g) — 14.9 — — — 22.3 Urethane-curingcatalyst Curing catalyst Isocyanurate- Type P15 P15 P15 P15 P15 P15 (D)forming Amount 80 80 80 80 80 80 catalyst (ppm) Urethane- Type DABCODABCO DABCO DABCO DABCO DABCO forming Amount 340 340 340 340 340 340catalyst (ppm) (E)/(B) — 0.28 — — — 0.64 Number average molecular weightin total 2000 1,780 2,000 4,000 1,000 1,600 of polyol (B) and polyol (E)Viscosity mPa · s 1,400 1,300 1,400 2,000 1,200 500 Height from point atwhich injected 5 5 5 5 5 5 polyurethane composition arrives todischarging outlet (mm) Distance from portion at which molding 5 5 5 5 55 drum and endless belt are first brought into contact to point at whichpolyurethane composition is injected (mm) Evaluation results Rubberhardness (IRHD°) 67 68 67 67 66 68 Hardness difference (difference(IRHD°) 0 0 0 0 0 0 between maximum value and minimum value) Surfacemark A A A A A A Intrusion of air bubble A A A A A A Intrusion offoreign matter A A A A A A Image results Ghost A A A A A A Image streakA A A A A A Example Example Item Example 7 Example 8 Example 9 10 11Preparation of prepolymer Polyisocyanate Type 4,4′-MDI 4,4′-MDI 4,4′-MDI4,4′-MDI 4,4′-MDI (A) Amount (g) 21.4 27.7 27.7 27.7 27.7 Polyol (B)Type PBA PBA PBA PBA PBA Number average 2,000 2,000 2,000 2,000 2,000molecular weight Amount (g) 66.4 52.7 52.7 52.7 52.7 NCO (%) 5.0% 8.8%8.8% 8.8% 8.8% Preparation of curing agent Chain extender Type 1,4-BD1,4-BD 1,4-BD 1,4-BD 1,4-BD (C) (1) Molecular weight 90.1 90.1 90.1 90.190.1 Amount (g) 1.6 2.6 2.6 2.6 2.6 Chain extender Type TMP TMP TMP TMPTMP (C) (2) Molecular weight 134.2 134.2 134.2 134.2 134.2 Amount (g)1.3 2.1 2.1 2.1 2.1 Polyol (E) Type PBA PBA PBA PBA PBA Number average1,000 1,000 1,000 1,000 1,000 molecular weight Amount (g) 9.3 14.9 14.914.9 14.9 Urethane-curing catalyst Curing catalyst Isocyanurate- TypeP15 P15 P15 P15 P15 (D) forming Amount 80 20 20 500 500 catalyst (ppm)Urethane- Type DABCO DABCO DABCO DABCO DABCO forming Amount 340 2001,500 200 1,500 catalyst (ppm) (E)/(B) 0.14 0.28 0.28 0.28 0.28 Numberaverage molecular weight in total 1,880 1,780 1,780 1,780 1,780 ofpolyol (B) and polyol (E) Viscosity mPa · s 3,000 1,400 1,400 1,4001,400 Height from point at which injected 5 5 5 5 5 polyurethanecomposition arrives to discharging outlet (mm) Distance from portion atwhich molding 5 5 5 5 5 drum and endless belt are first brought intocontact to point at which polyurethane composition is injected (mm)Evaluation results Rubber hardness (IRHD°) 66 66 69 65 68 Hardnessdifference (difference (IRHD°) 0 0 0 0 0 between maximum value andminimum value) Surface mark A A A A A Intrusion of air bubble A A A A AIntrusion of foreign matter A A A A A Image results Ghost A A A A AImage streak A A A A A

TABLE 2 Comparative Comparative Comparative Comparative Comparative ItemExample 1 Example 2 Example 3 Example 4 Example 5 Preparation ofprepolymer Polyisocyanate Type 4,4′-MDI 4,4′-MDI 4,4′-MDI 4,4′-MDI4,4′-MDI (A) Amount (g) 40.7 28.0 41.2 21.4 27.7 Polyol (B) Type PBA PBAPBA PBA PBA Number average 800 4,500 2,000 2,000 2,000 molecular weightAmount (g) 52.3 65.0 23.1 66.4 52.7 NCO (%) 8.8% 8.8% 20.0% 5.0% 8.8%Preparation of curing agent Chain extender Type 1,4-BD 1,4-BD 1,4-BD1,4-BD 1,4-BD (C) (1) Molecular weight 90.1 90.1 90.1 90.1 90.1 Amount(g) 3.9 3.9 4.7 1.6 2.6 Chain extender Type TMP TMP TMP TMP TMP (C) (2)Molecular weight 134.2 134.2 134.2 134.2 134.2 Amount (g) 3.2 3.2 3.91.3 2.1 Polyol (E) Type — — PBA PBA PBA Number average — — 1,000 1,0001,000 molecular weight Amount (g) — — 27.1 9.3 14.9 Urethane-curingcatalyst Curing catalyst Isocyanurate- Type P15 P15 P15 P15 P15 (D)forming Amount 80 80 80 80 15 catalyst (ppm) Urethane- Type DABCO DABCODABCO DABCO DABCO forming Amount 340 340 340 340 180 catalyst (ppm)(E)/(B) — — 1.17 0.14 0.28 Number average molecular weight in total 8004,500 1,460 1,880 1,780 of polyol (B) and polyol (E) Viscosity mPa · s550 2,000 420 3,800 1,200 Height from point at which injected 5 5 5 5 5polyurethane composition arrives to discharging outlet (mm) Distancefrom portion at which molding 5 5 5 5 5 drum and endless belt are firstbrought into contact to point at which polyurethane composition isinjected (mm) Evaluation results Rubber hardness (average (IRHD°) 60 6870 67 66 value) Hardness difference (difference (IRHD°) 0 2 3 3 5between maximum value and minimum value) Surface mark B C C C CIntrusion of air bubble B B C C B Intrusion of foreign matter B B B C AImage results Ghost C C C C C Image streak C C C C C ComparativeComparative Comparative Comparative Item Example 6 Example 7 Example 8Example 9 Preparation of prepolymer Polyisocyanate Type 4,4′-MDI4,4′-MDI 4,4′-MDI 4,4′-MDI (A) Amount (g) 27.7 27.7 27.7 27.7 Polyol (B)Type PBA PBA PBA PBA Number average 2,000 2,000 2,000 2,000 molecularweight Amount (g) 52.7 52.7 52.7 52.7 NCO (%) 8.8% 8.8% 8.8% 8.8%Preparation of curing agent Chain extender Type 1,4-BD 1,4-BD 1,4-BD1,4-BD (C) (1) Molecular weight 90.1 90.1 90.1 90.1 Amount (g) 2.6 2.62.6 2.6 Chain extender Type TMP TMP TMP TMP (C) (2) Molecular weight134.2 134.2 134.2 134.2 Amount (g) 2.1 2.1 2.1 2.1 Polyol (E) Type PBAPBA PBA PBA Number average 1,000 1,000 1,000 1,000 molecular weightAmount (g) 14.9 14.9 14.9 14.9 Urethane-curing catalyst Curing catalystIsocyanurate- Type P15 P15 P15 P15 (D) forming Amount 600 15 600 80catalyst (ppm) Urethane- Type DABCO DABCO DABCO DABCO forming Amount 1801520 1520 340 catalyst (ppm) (E)/(B) 0.28 0.28 0.28 0.28 Number averagemolecular weight in total 1,780 1,780 1,780 1,780 of polyol (B) andpolyol (E) Viscosity mPa · s 500 3,000 1,400 1,300 Height from point atwhich injected 5 5 5 5 polyurethane composition arrives to dischargingoutlet (mm) Distance from portion at which molding 5 5 5 Summit of drumand endless belt are first brought molding into contact to point atwhich drum polyurethane composition is injected (mm) Evaluation resultsRubber hardness (average (IRHD°) 62 67 65 66 value) Hardness difference(difference (IRHD°) 5 5 5 8 between maximum value and minimum value)Surface mark C C C C Intrusion of air bubble C B B C Intrusion offoreign matter B C C C Image results Ghost C C C C Image streak C C C C

According to the present invention, it is possible to provide theproduction method and the production apparatus, for continuously moldinga high-quality, electrophotographic blade member having lessirregularities of physical properties such as hardness and exhibitingless occurrence of marks in appearance and less occurrence of intrusionof air bubbles, by using the polyurethane composition for a short curingtime.

In addition, according to the present invention, it is possible toprovide the production apparatus that is capable of continuouslyproducing a high-quality, electrophotographic blade member using apolyurethane resin including a polyurethane composition for a shortcuring time, the production apparatus exhibiting high productionefficiency, having such a structure as easily realizing automation, andcontributing to reducing facility cost.

Besides, according to the present invention, it is possible to providethe inexpensive, high-quality blade not only to the field ofelectrophotographic technology but also to other fields in which bladesare used.

While the present invention has been described with reference toexemplary embodiments, it is to be understood that the invention is notlimited to the disclosed exemplary embodiments. The scope of thefollowing claims is to be accorded the broadest interpretation so as toencompass all such modifications and equivalent structures andfunctions.

This application claims the benefit of Japanese Patent Applications No.2010-072928, filed Mar. 26, 2010, and No. 2010-256854, filed Nov. 17,2010 which are hereby incorporated by reference herein in theirentirety.

1. A method of producing an electrophotographic blade member,comprising: a mixing and stirring step; an injection step; athermosetting step; a releasing step; and a cutting step, the methodusing a molding drum having formed a continuous molding groove on anouter peripheral surface thereof and an endless belt which is broughtinto contact with a part of the outer peripheral surface of the moldingdrum, wherein: the electrophotographic blade member is made of apolyurethane resin, which is obtained by thermosetting a polyurethanecomposition containing at least the following: (A) a polyisocyanate; (B)an adipate-based polyester polyol having a number average molecularweight of 1,000 to 4,000; (C) a chain extender having a molecular weightof 200 or less; and (D) an isocyanurate-forming catalyst at 20 ppm ormore and 500 ppm or less and a urethane-forming catalyst at 200 ppm ormore and 1,500 ppm or less as curing catalysts, wherein the polyurethanecomposition has a viscosity of 500 mPa·s or more and 3,000 mPa·s or lessafter completion of the mixing and stirring step and before theinjection step; and wherein in the injection step, an arrangementposition of the polyurethane composition is set, on the endless belt, ata position opposing to the molding groove, the position being away froma position at which the molding drum and the endless belt are firstbrought into contact with each other on an upstream side with respect toa moving direction of the endless belt.
 2. The method of producing anelectrophotographic blade member according to claim 1, wherein: thearrangement position of the polyurethane composition is set, on theendless belt, at a position opposing to the molding groove, the positionbeing 5 mm or more and 350 mm or less away from the position at whichthe molding drum and the endless belt are first brought into contactwith each other on the upstream side with respect to the movingdirection of the endless belt; and a discharge position of thepolyurethane composition is set to a position 5 mm or more and 200 mm orless above the arrangement position in a vertical direction.
 3. Themethod of producing an electrophotographic blade member according toclaim 1, wherein: the polyurethane composition further contains: (E) apolyol having a number average molecular weight smaller than the numberaverage molecular weight of the adipate-based polyester polyol (B) andlarger than the molecular weight of the chain extender (C).
 4. Themethod of producing an electrophotographic blade member according toclaim 3, wherein: (E)/(B), which is a mass ratio of the polyol (E) tothe adipate-based polyester polyol (B), both being contained in thepolyurethane composition, is 0.02 or more and 0.60 or less; and a numberaverage molecular weight of mixed polyol of the adipate-based polyesterpolyol (B) and the polyol (E) is 1,000 to or more and 3,000 or less. 5.The method of producing an electrophotographic blade member according toclaim 1, wherein the molding drum is subjected to releasing treatment atleast at a portion with which the polyurethane composition is broughtinto contact.
 6. The method of producing an electrophotographic blademember according to claim 1, wherein the endless belt is subjected toreleasing treatment at least at a portion with which the polyurethanecomposition is brought into contact.
 7. The method of producing anelectrophotographic blade member according to claim 1, wherein a bottomsurface of the molding groove of the molding drum comprises a roughsurface portion at least at one corner.
 8. An apparatus for producing anelectrophotographic blade member, comprising: a mixing and stirringunit; an injection unit; a thermosetting unit; a releasing unit; and acutting unit, wherein the apparatus uses a molding drum comprising acontinuous molding groove in an outer peripheral surface and an endlessbelt brought into contact with a part of the outer peripheral surface ofthe molding drum, wherein: the electrophotographic blade member is madeof a polyurethane resin, which is obtained by thermosetting apolyurethane composition containing at least the following: (A) apolyisocyanate; (B) an adipate-based polyester polyol having a numberaverage molecular weight of 1,000 to 4,000; (C) a chain extender havinga molecular weight of 200 or less; and (D) an isocyanurate-formingcatalyst at 20 ppm or more and 500 ppm or less and a urethane-formingcatalyst at 200 ppm or more and 1,500 ppm or less as urethane-curingcatalysts, wherein the polyurethane composition has a viscosity of 500mPa·s or more and 3,000 mPa·s or less after completion of the mixing andstirring and before the injection; wherein the injection unit isarranged above the endless belt; and wherein the polyurethanecomposition is arranged at, on the endless belt, a position opposed tothe molding groove, the position being away from a portion at which themolding drum and the endless belt are first brought into contact witheach other on an upstream side with respect to a moving direction of theendless belt.